Abstract: A belt polishing machine has a moving endless abrasive coated polishing belt that wraps around and travels over a substantial portion of a circumferential surface of a rotatable workpiece for finishing the surface. A drive pulley drives the polishing belt in a continuous path at a desired surface speed over the circumferential surface of the workpiece while the workpiece is being rotated at a desired rotational speed. Guide pulleys direct the polishing belt around and into engagement with a substantial portion of the circumferential surface and may supply tension to the polishing belt during finishing operations. Separate tensioning pulleys may be provided. A coolant feed applies coolant against the polishing belt for separating and carrying away removed material from the belt and cleaning the abrasive for a subsequent pass. A backup shoe may be provided to selectively apply additional pressure through the belt upon portions of the polished surfaces to improve cylindricity.

Abstract: A tubular shaft has a portion of reduced inner diameter at a location where joining to an apertured member is desired. The aperture in the member is lobed with splines in the lobes and has an undercut groove or grooves, and is hardened. The shaft is inserted in the aperture and the reduced inner diameter portion is expanded to force the shaft material into the lobes and groove and around the splines to form a connection which resists torque and axial separation. The tube expansion is effected by forcing a series of balls through the reduced diameter portion, each ball being slightly larger than the reduced diameter and larger than the previous ball but smaller than the remainder of the shaft I.D. A crankshaft is assembled with this method wherein counterweights have lobed apertures to receive end portions of crank pins and main journals having reduced I.D.'s.

Abstract: A crankshaft for a two stroke engine requiring a seal disc on each crank pin is formed by forging, machining and heat treating without a seal disc and then applying a two part seal disc to each crank pin. The two parts of the seal disc have a mating interface in line with the center of the crank pin and a semi-circular recess in each part surrounds half of the crank pin. The parts are dimensioned to effect an interference fit on the crank pin when assembled with sufficient force. The parts are secured together by laser welding, bolts or by adhesive bonding. In the case of welding, the parts are assembled with dowels normal to the interface to maintain the proper alignment during welding and to reinforce the strength of the final assembly.

Abstract: A tubular shaft has a portion of reduced inner diameter at a location where joining to an apertured member is desired. The aperture in the member is lobed with splines in the lobes and has an undercut groove, or groove and is hardened. The shaft is inserted in the aperture and the reduced inner diameter portion is expanded to force the shaft material into the lobes and groove and around the splines to form a connection which resists torque and axial separation. The tube expansion is effected by forcing a series of balls through the reduced diameter portion, each ball being slightly larger than the reduced diameter and larger than the previous ball but smaller than the remainder of the shaft I.D. A crankshaft is assembled with this method wherein counterweights have lobed apertures to receive end portions of crank pins and main journals having reduced I.D.'s.

Abstract: A lightweight composite camshaft has stamped sheet metal or other lightweight journal and/or cam elements having locating hubs and assembled onto a hollow tube. An economical and rapid method of assembly uses indexing balls pressed into accurately positioned blind holes in the tube and grooves in the bores or hubs of the cam elements to angularly locate the cams with precision prior to locking them tightly in place by expansion of the tube.

Abstract: Camshaft assemblies are disclosed with methods for making them by the expansion of tubular shafts into prelocated cams, journals and other elements, if desired. Features of the camshafts include trilobe or polylobe element openings, preferably splined or serrated for low energy filling and high torque capacity and High Strength Low Alloy mild steel tubular shaft material.

Abstract: Camshaft assemblies, methods and apparatus are provided for making camshafts by the expansion of tubular shafts into prelocated cams, journals and other elements, if desired. Features of the camshafts include trilobe or polylobe element openings, preferably splined or serrated for low energy filling and high torque capacity and high strength low alloy mild steel tubular shaft material. The method emphasizes trapping, or loading, the shaft to prevent axial lengthening during expansion such as by mechanical ballizing. The apparatus includes adjustable thrust blocks and locating plungers with incorporated flush pin gages together with hydraulic or other loading means all for use in carrying out the assembly method with various benefits from the incorporated features.

Abstract: Camshaft assemblies, methods and apparatus are provided for making camshafts by the expansion of tubular shafts into prelocated cams, journals and other elements, if desired. Features of the camshafts include trilobe or polylobe element openings, preferably splined or serrated for low energy filling and high torque capacity and High Strength Low Alloy mild steel tubular shaft material. The method emphasizes trapping, or loading, the shaft of prevent axial lengthening during expansion such as by mechanical ballizing. The apparatus includes adjustable thrust blocks and locating plungers with incorporated flush pin gages together with hydraulic or other loading means all for use in carrying out the assembly method with various benefits from the incorporated features.

Abstract: An improved crankcase structure for engine blocks and the like, may be fabricated wherein the crankcase is initially cast or otherwise formed with bearing caps integral therewith. The caps are preferably secured by severable connecting portions unidirectionally longitudinally adjacent their associated bearing receiving portions in the transverse webs of the cylinder block. The complete crankcase is then machined and the bearing caps are separated for subsequent assembly to the crankcase in conventional fashion. Consequently, the invention reduces the amount of tooling and machining time and equipment required for manufacturing crankcases for engine blocks and the like.

Abstract: An improved crankcase structure and manufacturing method for engine blocks and the like wherein the crankcase is initially cast or otherwise formed with bearing caps integral therewith. The caps are preferably secured by severable connecting portions unidirectionally longitudinally adjacent their associated bearing receiving portions in the transverse webs of the cylinder block. The complete crankcase is then machined and the bearing caps are separated for subsequent assembly to the crankcase in conventional fashion. The invention reduces the amount of tooling and machining time and equipment required for manufacturing crankcases for engine blocks and the like.